Precast modular living habitat

ABSTRACT

A precast modular element of continuous reinforced concrete slab, of varying composition and thickness and of diverse shapes and sizes, forming a volumetric piece with regular or irregular prismatic shape, with support beams made of the same material integrated to the external part of the lower face, wherein the element may be cast in factory or in place, and may be used alone or with other similar elements in one or two levels as rooms, houses or other purposes, wherein it is characterized by the use of the following materials or compounds for the continuous slab: support beams, floors, walls and roofing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to Argentinian utility patent application number 20110103863 filed Aug. 13, 2015 titled “Precast Modular Living Habitat”. The subject matter of patent application number 20110103863 is hereby incorporated by reference in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

Not Applicable.

SUMMARY

A precast modular element is provided. This Summary is provided to introduce a selection of disclosed concepts in a simplified form that are further described below in the Detailed Description including the drawings provided. This Summary is not intended to identify key features or essential features of the claimed subject matter. Nor is this Summary intended to be used to limit the claimed subject matter's scope.

In one embodiment, the claimed subject matter comprises a precast modular element of continuous reinforced concrete slab, of varying composition and thickness and of diverse shapes and sizes, forming a volumetric piece with regular or irregular prismatic shape, with support beams made of the same material integrated to the external part of the lower face, wherein the element may be cast in factory or in place, and may be used alone or with other similar elements in one or two levels as rooms, houses or other purposes, wherein it is characterized by the use of the following materials or compounds for the continuous slab: support beams, floors, walls and roofing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a U-shaped modular element, in accordance with one embodiment;

FIG. 2 is an illustration of an L-shaped modular element, in accordance with one embodiment;

FIG. 3 is an illustration of another L-shaped modular element, in accordance with another embodiment;

FIG. 4 is an illustration of another U-shaped modular element, in accordance with another embodiment;

FIG. 5 is an illustration of another L-shaped modular element, in accordance with another embodiment;

FIG. 6 is an illustration of another L-shaped modular element, in accordance with another embodiment;

FIG. 7 is an illustration of another U-shaped modular element, in accordance with another embodiment;

FIG. 8 is an illustration of joints between two similar modular elements, in accordance with another embodiment;

FIG. 9 is an illustration of a cross section of a modular element, in accordance with another embodiment;

FIG. 10 is an illustration of a coupling of L-shaped and U-shaped floors with the first “L” or “U” modular element installed, in accordance with another embodiment;

FIG. 11 is an illustration of movement of 2 or 3 external lateral molds, in accordance with another embodiment; and

FIG. 12 is an illustration of a technique to lift the “L” or “U” modular element through slings, in accordance with another embodiment.

DETAILED DESCRIPTION

The following detailed description refers to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While embodiments may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the claimed subject matter. Instead, the proper scope of the claimed subject matter is defined by the appended claims.

This utility model refers to a precast modular element of continuous reinforced concrete slab, of varying composition and thickness and of diverse shapes and sizes, forming a volumetric piece with regular or irregular prismatic shape, with support beams made of the same material integrated to the external part of the lower face. It may be placed on the ground, piles or other foundations, forming air chambers between the precast modular element and the ground (in the spaces between the beams), being this the main purpose of the claimed subject matter. Various internal and external finishing materials may be added to the element so as to be transported or cast in place. The element can be placed alone or with other similar elements in one or two levels as rooms, houses or other purposes, depending on the project.

FIG. 1 illustrates a perspective view of the different versions of the modular element called “U”, forming a continuous reinforced concrete faced slab (1), with integrated support beams (2), which shall not be integrated if the modular element is placed on other element with flat ceiling slab (4), the rear face (3), one of the faces of the flat ceiling slab (4) or with a single slope slab (5) and lateral faces (6) or (7), foundation of the versions of a continuous slab with spaces left (8) for doors and/or windows on the rear face and/or lateral faces in the cast of the proposed modular element.

FIG. 2 illustrates a perspective view of one of the versions of the modular element called “L”, with l-shaped floor, with flat ceiling slab (4), with a single right-side wall (6), forming a continuous reinforced concrete faced slab (1) with integrated support beams (2) and lateral faces (3), (4) and (6), with spaces left (8) for doors and/or windows on the rear face and/or lateral face.

FIG. 3 illustrates a perspective view of one of the versions of the modular element called “L”, with l-shaped floor, with flat ceiling slab (4), with a single left-side wall (7), forming a continuous reinforced concrete faced slab (1) with integrated support beams (2), (3), (4) and (7), with spaces left (8) for doors and/or windows on the rear face and/or lateral face.

FIG. 4 illustrates a perspective view of one of the versions of the modular element called “U”, with U-shaped floor, with flat ceiling slab (4), with two lateral walls (6) and (7), forming a continuous reinforced concrete faced slab (1) with integrated support beams (2), (3), (4), (6), and (7), with spaces left (8) for doors and/or windows left on the rear face and/or lateral faces.

FIG. 5 illustrates a perspective view of one of the versions of the modular element called “L”, with l-shaped floor, with a single slope slab (5), with a single right-side wall (7), forming a continuous reinforced concrete faced slab (1) with integrated support beams (2), which shall not be integrated if the modular element is placed on other element with flat ceiling slab (4), (3), (5) and (7) with spaces left (8) for doors and/or windows on the rear face and/or lateral face.

FIG. 6 illustrates a perspective view of one of the variants of the modular element called “L”, with a l-shaped floor, with a single slope slab (5), with a single left-side wall (6), forming a continuous reinforced concrete faced slab (1) with integrated support beams (2), which shall not be integrated if the modular element is placed on other element with flat ceiling slab (4), (3), (5) and (6) with spaces left (8) for doors and/or windows on the rear face and/or lateral face.

FIG. 7 illustrates a perspective view of one of the versions of the modular element called “U”, with U-shaped floor, with a single slope slab (5), with two lateral walls (6) and (7), forming a continuous reinforced concrete faced slab (1) with integrated support beams (2), which shall not be integrated if the modular element is placed on other element with flat ceiling slab (4), (3), (5), (6) and (7), with spaces left (8) for doors and/or windows in the rear face and/or lateral face, left in the cast of the proposed modular element.

FIG. 8 illustrates a perspective view of a version of the joints between two similar modular elements through walls (3) with (3) and/or (6) with (6) and/or (7) with (7), by means of galvanized threaded rods (14), tearing apart the horizontally expanded polystyrene (10) in both modular elements so as to be pushed through holes (16) left in the casting of precast elements, the threaded rods (14), before the installation of a closing element, sealant, adhesive, etc. (17) in all the surface which shall be in contact with the modular elements and the adjusting of nuts on both faces.

Every threaded rod shall be covered by the inner coating (12).

FIG. 9 illustrates a cross section on a scale larger than the one of the previous images. It details a version of the composition of the continuous reinforced concrete slab (3), (4), (5), (6) or (7), with a coating all over the external surface such as an elastic and water-repellent membrane (9), sheets of expanded polystyrene (10) as thick as the required K coefficient, iron electro welded meshes and rods (according to the structural calculation) with additional iron reinforcements for possible different movements during transport and assembly (11) and the inner coating made of several materials (12).

FIG. 10 illustrates, on a small scale and in different floors, the possible coupling of l-shaped and u-shaped floors with the first “L” or “U” modular element installed, according to the expansion/modification needs of the project, etc., taking into account the lateral slope of the roof slabs.

FIG. 11 illustrates a schematic and perspective view of the movement of 2 or 3 external lateral molds (a), according to the versions of the projects and the whole internal mold (b) to cast the modular element.

FIG. 12 illustrates a perspective view of an example of one of the techniques to lift the “L” or “U” modular element through slings (18) incorporated to the “hanger” of (19) a crane jib (20) after the casting and the setting time required to be lifted and left on the ground, piles, etc.

With regard to technical resources used, the appearance on the market of cranes or crane jibs incorporated to trucks together with additives and self-compacters as fluidizers to be incorporated to the reinforced concrete, which improve and control the casting with low or high temperatures and with internal or external molds which allow to obtain with a single casting a regular or irregular volumetric prismatic piece formed by the support beams, the floor, the walls, the coating, are the principle of the claimed subject matter, enabling them to be cast in factory and transported or to be cast in place and coupled with the crane depending on the project.

With regard to needs which led to the claimed subject matter, to provide one-store or two-stores houses for people with very low purchasing power, easy to manufacture and set-up using reinforced concrete as base material (facility to obtain the materials), with only one casting for every modular element (support beams, floor, walls and coating) with low labor and therefore with costs 50% lower than the ones for similar traditional houses—concrete is a material with a cost lower than other materials, unskilled labor and incorporated coating. These houses facilitate self-construction, are easily and fast enlarged, need no maintenance and have bioclimatic properties that traditional houses usually do not have (because of the use of expanded polystyrene in the walls and air chambers below the floor slab between the support beams)

The possibility to couple one or more modular elements to existing houses in a very fast way in order to solve any immediate housing problem.

It is also possible to deliver one or more modular elements with or without finishes, so the user himself may continue, reducing the cost even more.

Another advantage of the claimed subject matter is its simple and minimum infrastructure for casting and assembling since it only needs the molds (in a quantity proportional to the houses/time required) and a 25T truck crane and unskilled labor carried out by work cooperatives which shall employ staff and shall also have houses for their own workers, for mutual assistance associations, municipalities or other purposes.

Once the precast modular element of continuous reinforced concrete slab, of varying composition and thickness and of diverse shapes and sizes, forming a volumetric piece with regular or irregular prismatic shape, with support beams made of the same material integrated to the external part of the lower face, which may be transported or cast in place, and may be used alone or with other similar elements in one or two levels as rooms, houses or other purposes is used, modifications and/or improvements may be made in the different versions of the element. Such modifications or improvements shall be included in the scope of protection determined in the main parts of the claims.

Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. 

What is claimed is:
 1. A precast modular element of continuous reinforced concrete slab, of varying composition and thickness and of diverse shapes and sizes, forming a volumetric piece with regular or irregular prismatic shape, with support beams made of the same material integrated to the external part of the lower face, wherein the element may be cast in factory or in place, and may be used alone or with other similar elements in one or two levels as rooms, houses or other purposes, wherein it is characterized by the use of the following materials or compounds for the continuous slab: support beams, floors, walls and roofing.
 2. The precast modular element of claim 1, wherein it is characterized by casting the continuous slab in various regular or irregular volumetric prismatic shapes.
 3. The precast modular element of claim 2, wherein it is characterized by the element having different internal and external sizes depending on the use.
 4. The precast modular element of claim 3, wherein it is characterized by coupling the modular elements among each other with different volumetric shapes as the l-shaped floors and u-shaped floors, etc., in one and/or two levels.
 5. The precast modular element of claim 4, wherein it is characterized by having three, two or only one wall formed by the continuous slab with the floor slab and the roof slab.
 6. The precast modular element of claim 5, wherein it is characterized by having many support beams with various shapes and sizes integrated to the external part of the rear face.
 7. The precast modular element of claim 6, wherein it is characterized by the modular element being cast without one of the faces so as to be removed from the internal mold after casting in any of the faces which form the walls in l-shaped and u-shaped floors, etc.
 8. The precast modular element of claim 7, wherein it is characterized by the modular elements being cast in factory or in the assembly site, through molds made of different materials and/or with various movement mechanisms, automations, 3D printers, etc.
 9. The precast modular element of claim 8, wherein it is characterized by the modular elements being cast in removable molds so as to be removed through the door openings, getting a closed regular or irregular prismatic shape with all its faces.
 10. The precast modular element of claim 9, wherein it is characterized by the support beams being cast with materials other than the materials of the modular element but they are always integrated to same. 